LIQUIFIRE TECHNICAL MANUAL TM-1217(Nov-81)

1 LIQUIFIRE . TECHNICAL MANUAL . TM-1217 (Nov-81). CONTENTS. SECTION 10 - GENERAL SECTION 50 - POWER TRAIN. Group 05 - Snowmobile Identification Group 05 - General Information Group 10 - Specifications Group 10 - 102C Drive Sheave Group 15 - Tune-Up and Adjustments Group 12 - John Deere (TRBOO) Drive Sheave Group 20 - Break-In, Fuel and Lubricants Group 15 - John Deere Driven Sheave Group 20 - Drive Belt SECTION 20 - ENGINE Group 25 - Chain Case, Secondary Shaft and Group 05 - General Information Drive Shaft Group 10 - Basic Engine Group 30 - Mechanical Disk Brake Group 15 - Cooling System Group 35 - Specifications Group 20 - Recoil Starter Group 25 - Specifications SECTION 60 - SUSPENSION. Group 05 - General Information SECTION 30 - FUEL SYSTEM Group 10 - Slide Suspension Group 05 - General Information Group 15 - John Deere Track Group 10 - Mikuni Carburetor Group 20 - Skies and Steering Group 15 - Oil Injection System Group 25 - Specifications Group 20 - Fuel Pump, Fuel Tank, Screen and In-Line Fuel Filter SECTION 70 - SERVICE TOOLS.

2 Group 05 - Essential Service Tools SECTION 40 - ELECTRICAL SYSTEM Group 10 - Convenience Service Tools Group 05 - General Information Group 10 - Capacitor Discharge Ignition (Serial No. 120,001-190,000). Group 12 - Capacitor Discharge Ignition (Serial No. 190,000- ). Group 15- Lighting System and Switches Group 20 - Specifications 2A8; M22;CONT A 280981. Litho in TM-1217 (Nov-81). Contents Utho in TM-1217 (Nov-81). Section 10. GENERAL. CONTENTS. Page Page GROUP 05 - GENERAL INFORMATION GROUP 15 - TUNE-UP AND ADJUSTMENTS. Snowmobile Serial Number .. 10-05-01 Tune-Up and Adjustments .. 10-15-01. Engine Serial Number 10-05-01 Adjustments .. 10-15-01. Vintage Information .. 10-05-01 Spark Plug Recommendation .. 10-15-01. GROUP 10 - SPECIFICATIONS GROUP 20 - BREAK-IN, FUEL AND LUBRICANTS. Snowmobile Specifications 10-10-01 Break-In Period .. 10-20-01. Engine Specifications .. 10-10-02 Fuel and Oil .. 10-20-01. Lubricants 10-20-01. Capacities and Service Intervals 10-20-02.

3 2A8; M22;100SA A 280981. Litho in 10-00-01 TM-1217 (Nov-81). Contents Litho in 10-00-02 TM-1217 (Nov-81). Group 05. GENERAL INFORMATION. SNOWMOBILE SERIAL NUMBER. The machine serial number is stamped into the right-hand side of the tunnel. 2A8;M24912 M22;1005A B 280981. ENGINE SERIAL NUMBER. The engine serial number is stamped into the upper crankcase half. VINTAGE INFORMATION. 1980 model Year 1981 model Year Snowmobile liqulfire Snowmobile LIQUIFIRE Serial Number J44LJ 120001M Serial Number J44LK 155001 M. Code No. (Type) J44LJ Code No. (type) J44LK. Engine Manufacturer John Deere Fireburst* Engine Manufacturer John Deere Fireburst*. Engine model No. TC440-A Piston Ported Engine model No. TC440A Piston Ported 1982 model Year Snowmobile Liqulfire Serial Number J44LL 190001 M. Code No. (type) J44LL. Engine Manufacturer John Deere Fireburst*. Engine model No. TC440A Piston Ported * Manufactured for John Deere by Kawasaki Heavy Industries, Japan 2AB; M22;1005A D 2101 2.

4 Litho in 10-05-01 TM-1217.{Nov-81). I General Information Litho in 10-05-02 TM-1217 (Nov-81). Group 10. SPECIFICATIONS. SNOWMOBILE SPECIFICATIONS. FUEL SYSTEM POWER TRAIN. Fuel Tank Capacity ( L) Transmission.. Two-sheave variable gals Drive Sheave .. John Deere (Comet) 102C** or Mixing Ratio 50:1 * John Deere (TR800). Oil Tank Capacity ( L) 3-1/2 pints Secondary Sheave.. John Deere Filters Two located in pick-up line Final Drive Enclosed Chain Fuel Pump: Standard Ratio: :1 or Mikuni .. Impulse-type located :1. in the inlet line Brake .. Mechanical Disk Oil Pump: Stop Light. Standard Mikuni " .. Reciprocating-plunger driven by the engine SUSPENSION. Carburetor .. Mikuni Suspension .. Slide Rail Drive Sprockets.. Compression-Molded LIQUID COOLING SYSTEM Polyethelene Capacity .. ( L) 3 qts. Track Yokohama Type .. Pressurized system with Track Material.. Rubber centrifugal pump Track Width.. ( em) 15 in. Engine Temperature Control. One thermostat Track Drive lnvolute Pump Output (74 L) gpm at 7000 engine rpm CHASSIS AND BODY.}

5 Coolant Filler Cap ( to kPa) Tunnel Aluminum 12 to 13 psi Pan .. Steel and TPR. Hood.. Sheet Molding Compound ELECTRICAL SYSTEM Windshield .. Polyearbonate Charge System 0 Flywheel Alternator Overall length .. ( em) 102 in. Capacity.. 120 Watts Overall Width ( cm) 39 in.). Ignition System 0 Capacitor Discharge Overall Height.. ( em) 35 in. Ignition Timing.. Align Mark on Stator Weight (Approx.) 0 ( kg) 404 Ibs. with mark on crankcase. Plug Gap .. ( mm) in. Spark Plug N-2 or QN-2. ,.. First tank of fuel and operation below -20 F. (-29 C). **Manufactured for John Deere by Comet Industries, Richmond, Indiana 2A8; M22;1010A A 280981. Litho in 10-10-01 TM-1217 (Nov-81). Specifications ENGINE SPECIFICATIONS. ITEM 440 LIQUIFIRE . Engine model TC440A Piston Ported Enqine Manufacturer John Deere Fireburst*. Type of Engine Two-Stroke, Liquid-Cooled Number of Cylinders Two Cylinder Sleeve Chrome Bore (mm) 68. Stroke (mm) 60. Displacement (ee) 436. Compression Ratio :1.

6 Ignition Type Capacitor Discharge Ignition Manufacturer Kokusan Lighting Coil Output 120 Watt Carburetor Manufacturer Mikuni Carburetor model VM36/85/, VM36/108, VM36/121, VM36/122. Starting System Recoil Start "'Manufactured for John Deere by Kawasaki Heavy Industries, Japan. 2A8; M22;1010A B 280981. Litho in 10-10-02 TM-1217 (Nov-81). Group 15. TUNE-UP AND ADJUSTMENT. TUNE-UP AND ADJUSTMENT. Operation Specifications Reference Replace spark plugs Test for spark Section 40, Group 10. Champion QN-2 or N-2. DO NOT regap - replace Time ignition system Align mark on stator Section 40, Group 10. with mark on crankcase Adjust carburetor Select main jet Select power jet Adjust choke plunger Adjust throttle slide Section 30, Group 10. Adjust float height Adjust idle screw Adjust air jet Recondition carburetor Clean carburetor and Section 30, Group 10. install necessary parts. ADJUSTMENTS. Adjustment Specification Reference Brake Section 50, Group 30. Sheave alignment Section 50, Group 20.

7 Track Section 60, Group 15. Skis Section 60, Group 20. SPARK PLUG RECOMMENDATION. Use a Champion N-2 (AM52640) in the United States and a Champion QN-2 (AM55044) in Canada. These plugs are the only ones required for the 440 LIQUIFIRE engine. 2A8; M22;1015A A 280981. Litho in 10-15-01 TM-1217 (Nov-81). Tune-Up and Adjustment Litho in -10-15-02 TM-1217 (Nov-81). Group 20. BREAK-IN, FUEL AND LUBRICANTS. BREAK-IN PERIOD. Do not exceed 50 mph (80 km/h) for the first 100 miles (160. km) or force the machine at full throttle in deep snow. An occasional burst of power on hardpacked snow will not be harmful. For the first tank of fuel, pre-mix gasoline and oil in a 50:1. ratio and fill fuel tank. Fill the oil tank with John Deere 2-cycle oil. After break-in, use only gasoline in the fuel tank and 2-cycle oil in the oil tank. 2A8; M22;1020A A 280981. FUEL AND OIL. IMPORTANT: Use regular (leaded or non-leaded) gaso- line with an anti-knock index of 88 or higher. Regular (leaded) gasoline is pre- ferred but non-leaded gasoline is acceptable.

8 NEVER ALLOW OIL TANK TO BECOME EMPTY. Use John Deere 2-cycle oil. IMPORTANT: If other than John Deere 2-cycle oil is used, it must meet BIA (Boating Industry Association) test qualification TCW. IMPORTANT: When operating snowmobile at tempera- tures of _20 F (-29 C), use a 50:1 gaso- line and oil premix in the fuel tank an fill the oil tank with 2-cycle oil. DO NOT run straight gasoline in the fuel tank. The oil injeciton system may not function effi- cientlyat -20 F (-29 C) and this could cause engine failure. 2A8; M22;1020A B 280981. LUBRICANTS. 1. Park snowmobile on a level surface. 2. Remove lower plug. If oil flows from this hole, oil level is satisfactory. 3. To add oil, remove upper plug and add API-GL5 gear oil (SAE 90) until it flows from the lower hole. 4. Replace plugs. 2A8;M24954 M22;1020A C 280981. Litho in 10-20-01 TM-1217 (Nov-81). Break-In, Fuel and Lubricants CAPACITIES AND SERVICE INTERVALS. Fuel Tank ( L) gal. Oil Tank ( L) 3-1/2 pte Gear Case (40 ee) oz.

9 Chain Case (Oil Change) 200 hours, 2 years or (1609 kms) 1000 miles Gear Case (Oil Change).. Annually 2A8; M22;1020A 0 290981. Litho in 10-20-02 TM-1217 (Nov-81). Section 20. ENGINE. CONTENTS. Page Page GROUP 05 - GENERAL INFORMATION GROUP 15 .. COOLING SYSTEM. Power Stroke .. 20-05-01 General Information 20-15-01. Exhaust Stroke 20-05-01 Test System Fuel Transfer Stroke 20-05-01 Test Filler Cap 20-15-03. Compression and Intake Stroke 20-05-01 Drain Cooling System 20-15-03. Diagnose Malfunctions 20-05-02 Fill Cooling System Engine Spark Test 20-05 ..03 Check or Replace Thermostat .. 20-15-04. Engine Compression Test.. 20-05 ..03 Repair Radiator .. 20-15-05. Replace Heat Exchanger 20-15-05. GROUP 10 - BASIC ENGINE. Remove Engine 20-10 ..01 GROUP 20 .. RECOIL STARTER. Disassemble Engine .. Remove Starter.. 20-20-01. Inspect Cylinder Heads 20-10-06 Disassemble Starter.. 20-20-01. Inspect Cylinders Assemble Starter 20-20-02. Inspect Pistons and Rings 20-10-08 Install Starter.

10 20-20-05. Inspect Crankshaft 20-10-09. Replace Outer Crankshaft Bearings .. 20-10-09 GROUP 25 - SPECIFICATiONS. Inspect Crankcase 20-10-10 Engine Specifications.. 20-25-01. Install Crankshaft 20-10-10 Spark Plug Specifications 20-25-01. Measure Crankshaft End Play 20-10-11 Torque Specifications 20-25-02. Install Lower Crankcase Half 20-10-11. Install Pistons 20-10-11. Install Cylinders and Heads 20-10-12. Check Crankshaft Runout .. Install Oil Injection Pump 20-10-12. Install Stator 20-10-15. Install Flywheel 20-10-15. Install Flywheel Housing 20-10-16. Install Exterior Components 20-10-16. Pressure Test Engine Install Engine 20-10-17. 2AS; M22;2000A A 290981. Litho in 20-00-01 TM-1217 (Nov-81). Contents Litho in 20-00-02 TM-1217 (Nov-81). Group 05. GENERAL .INFORMATION. POWER STROKE. NOTE: Power, exhaust and fuel transfer all occur on the downstroke and compression and intake occur on the upstroke.. Slightly before top-dead center (TOe) ignition occurs.